Polymeric web exhibiting a soft and silky tactile impression

ABSTRACT

A polymeric web exhibiting a soft and silky tactile impression on at least one side thereof is disclosed. The silky feeling side of the web exhibits a pattern of discrete hair-like fibrils, each of the hair-like fibrils being a protruded extension of the web surface and having a side wall defining an open proximal portion and a closed distal portion. The hair-like fibrils exhibit a maximum lateral cross-sectional diameter of between 2 and 5 mils, and an aspect ratio from 1 to 3. Methods and apparatus for making the polymeric web utilize a three-dimensional forming structure having a plurality of protrusions being generally columnar forms having an average aspect ratio of at least about 1.

FIELD OF THE INVENTION

The present invention relates to a polymeric web exhibiting a soft andsilky tactile impression on at least one surface. More particularly, thepresent invention relates a three-dimensional polymeric web exhibiting asoft and silky tactile impression that can be used as a body-facingtopsheet in disposable absorbent.

BACKGROUND OF THE INVENTION

It is extremely desirable to construct disposable articles, such asabsorptive devices, including sanitary napkins, pantyliners, interlabialdevices, diapers, training pants, incontinent devices, wound dressingsand the like, with a soft cloth-like surface feel to the user's skin atany anticipated points of contact. Likewise, it has long been known inthe disposable articles art to construct absorptive devices that presenta dry surface feel to the user, especially during use. By having a soft,cloth-like body-facing surface that retains a dry surface feel duringuse, an absorptive device gives improved wearing comfort, and minimizesthe development of undesirable skin conditions due to prolonged exposureto moisture absorbed within the absorptive device.

While woven and non-woven fibrous webs are often employed as body-facingtopsheets for absorptive devices because of their pleasant surface feel,macroscopically expanded, three dimensional, apertured polymeric webssuch as the commercially successful DRI-WEAVE™ topsheet marketed byProcter & Gamble Company have also been utilized. One viable polymericweb of this type is disclosed in U.S. Pat. No. 4,342,314 issued to Radelet al. on Aug. 3, 1982. Such webs have been shown to exhibit desirablefluid transport and fluid retaining characteristics. Desirable fluidtransport characteristics allow the topsheet to acquire fluids, such asurine or menses, and pass to fluid into the absorptive article. Onceabsorbed-into the absorptive article, the fluid retaining feature of thetopsheet preferably prevents rewet, i.e., the movement of fluid backthrough the topsheet. Rewet can be a result of at least two causes: (1)squeezing out of the absorbed fluid due to pressure on the absorptivearticle; and/or (2) wetness entrapped within or on the topsheet.Preferably, both properties, fluid acquisition and fluid retention, aremaximized. Said differently, preferably a topsheet will exhibit highrates of fluid acquisition, and low levels of rewet.

Other macroscopically expanded, three dimensional, apertured polymericwebs are known. For example, U.S. Pat. No. 4,463,045 issued to Ahr etal. on Jul. 31, 1984 discloses a macroscopically expandedthree-dimensional polymeric web that exhibits a substantially non-glossyvisible surface and cloth-like tactile impression. Ahr et al. teachesthe criteria which must be met with respect to the regularly spacedpattern of surface aberrations in order to diffusely reflect incidentlight and thereby eliminate gloss. Ahr, et al teaches that the surfaceaberrations in the web should exhibit an average amplitude of at leastabout 0.2 mils (i.e., 0.0002 inches), and most preferably at least about0.3 mils (i.e., 0.0003 inches) for a more clothlike or fiberlike tactileimpression in the resultant web. Despite its advancements in eliminatinggloss, the structure of the surface aberrations of the web in Ahr, etal. can lack desired softness. As recognized in the art, for example isU.S. Pat. No. 4,629,643, issued to Curro et al. (discussed below), thelack of desired softness is believed to be due to the structure of eachaberration, which can be described as having the properties of an “arch”that behaves as a discrete structural unit, resisting deflection. Thislack of sufficient deflection detracts from the softness impressionexperienced by the user's skin.

One proposed solution to improve the softness impression to the web ofAhr et al., was disclosed in the aforementioned U.S. Pat. No. 4,629,643(Curro, et al. '643) Curro, et al. '643 discloses a microaperturedpolymeric web exhibiting a fine scale pattern of discrete surfaceaberrations. Each of these surface aberrations have a maximum amplitudeand, unlike the web structure disclosed in Ahr, et al. at least onemicroaperature is provided that is substantially coincidental with themaximum amplitude of each surface aberration. The forming ofmicroapertures at the maximum amplitude of each surface aberrationprovides a volcano-like cusp with petal shaped edges. It is believedthat the resultant web surface that is in contact with the human skin isof smaller total area and is less resistant to compressive and shearforces than the unapertured “arch-like” structures taught by Ahr et al.

Although the microapertured film of Curro, et al. '643 imparts superiortactile impression to the skin of the user, it has some drawbacksrelated to certain fluid handling properties when used as a topsheet inabsorbent articles. For example, it has been found that a web asdisclosed in Curro, et al. '643, when used as a topsheet on a sanitarypad can permit an unacceptably high amount of rewet, i.e., fluid thatreturns back to the skin-facing surface of the topsheet after initiallyhaving passed through the topsheet to be absorbed by the sanitarynapkin. In particular, it appears that a web according to Curro '643 canbe more susceptible to rewet under pressure. This is because when such aproduct is used as a topsheet in a catamenial product, for example,absorbed fluid can be urged back out of the product through the manymicroapertures of the topsheet. It appears that each of themicroapertures in the structure of Curro, et al. '643 can provide apathway for fluid to escape from an underlying absorbent core in anabsorbent article under the pressure of normal wearing conditions. Thesepathways in the web structures therefore cause decreased fluid retentionand increased rewet in the absorbent structures.

Attempts at alleviating the shortcoming of Curro '643, i.e., attempts toboth maximize softness and reduce rewet, can be found, for example, inU.S. Pat. No. 6,228,462 issued to Lee, et al., on May 8, 2001. Leediscloses a compression resistant web comprising rigid polymers. Thecompression resistance of the rigid polymers helps reduce rewet, but therigid polymers utilized tend to decrease the softness of the web.

Furthermore, the hydroforming processes disclosed in Curro, et al. '643and Lee '462 for making macroscopically expanded, three dimensional,apertured polymeric webs results in a formed film that must be driedafter hydroforming. Due to the many interstices of the microaperturesthat can retain water, drying commercial quantities of these websconsumes significant amounts of energy, and can require significantcapital investments in drying equipment. One example of an approach toeffectively dry such webs is disclosed in U.S. Pat. No. 4,465,422 issuedSep. 22, 1987 to Curro, et al.

One further drawback associated with the webs disclosed in Curro '643and Lee '462 when used as topsheets on sanitary napkins is the tendencyof the microapertures to entrap fluid, such as menses. The entrapmentcan be in the microapertures themselves and/or between adjacentmicroapertures. Fluid so entrapped remains at or near the surface of theweb, and can, therefore be in contact with the wearer's skin forprolonged periods of time. This contact negatively affects the skinhealth of the wearer and causes the topsheet to not have a cleanappearance post-use.

Another attempt at making a soft, three-dimensional,macroscopically-expanded web having an improved functional surface isU.S. Pat. No. 5,670,110, issued to Dirk, et al. on Sep. 23, 1997. Theweb of Dirk et al. utilizes fibrils achieved via a screen printing roll.However, screen printing is a relatively slow process for makingcommercial webs for consumer articles.

Accordingly, it would be beneficial to have an improved formed film webthat has superior tactile impression and superior fluid handlingproperties.

Additionally, it would be beneficial to have a formed film web that hassuperior tactile impression and provides for superior fluid retentionand rewet characteristics.

Additionally, it would be beneficial to have a formed film web that hassuperior tactile impression and provides for superior cleanliness forhygiene articles.

Additionally, it would be beneficial to have an improved process formaking a formed film web that has superior tactile impression andprovides for superior fluid retention and rewet characteristics.

Finally, it would be beneficial to have an improved apparatus for use asa forming structure for forming a formed film web that has superiortactile impression and provides for superior fluid retention and rewetcharacteristics.

SUMMARY OF THE INVENTION

A polymeric web exhibiting a soft and silky tactile impression on atleast one side thereof is disclosed. The silky feeling side of the webexhibits a pattern of discrete hair-like fibrils, each of the hair-likefibrils being a protruded extension of the web surface and having a sidewall defining an open proximal portion and a closed distal portion. Thehair-like fibrils exhibit a maximum lateral cross-sectional diameter ofbetween 2 and 5 mils, and an aspect ratio from 1 to 3.

BRIEF DESCRIPTION OF THE DRAWING

While the specification concludes with claims particularly pointing outand distinctly claiming the subject matter of the present invention, itis believed that the invention will be better understood from thefollowing description taken in conjunction with the accompanyingFigures, in which:

FIG. 1 is an enlarged, partially segmented, perspective illustration ofa prior art polymeric web of the type generally disclosed in commonlyassigned U.S. Pat. No. 4,342,314.

FIG. 2 is an enlarged, partially segmented, perspective illustration ofa prior art polymeric web of the type generally disclosed in commonlyassigned U.S. Pat. No. 4,629,643.

FIG. 3 is an enlarged, partially segmented, perspective illustration ofa polymeric web of the present invention.

FIG. 4 is a further enlarged, partial view of a portion of the web shownin FIG. 3 illustrating in greater detail certain features of thepolymeric web of the present invention.

FIG. 5 is a cross-sectional depiction of a cross section taken alongSection 5-5 of FIG. 4.

FIG. 6 is a plan view of representative aperture shapes projected in theplane of the first surface of a polymeric web of the present invention.

FIG. 7 is a top plan view of a sanitary napkin with portions cut away tomore clearly show the construction of a catamenial device of the presentinvention.

FIG. 8 is a cross-sectional view of the sanitary napkin taken alongSection 8-8 of FIG. 7.

FIG. 9 is a simplified schematic illustration of a single phase formingprocess of the present invention.

FIG. 10 is an enlarged, partially segmented, perspective illustration ofa forming structure of the present invention.

FIG. 11 is a further enlarged, partial view of a portion of the formingstructure shown in FIG. 10.

FIG. 12 is a further enlarged partial view of a portion of the formingstructure shown in FIG. 11.

FIG. 13 is a photomicrograph of one embodiment of a forming structure ofthe present invention.

FIG. 14 is an enlarged view of a portion of the forming structure ofFIG. 13.

FIG. 15 is a photomicrograph of another embodiment of a formingstructure of the present invention.

FIG. 16 is an enlarged view of a portion of a forming structure similarto that shown in FIG. 15.

FIG. 17 is a photomicrograph of a portion of a web of the presentinvention.

FIG. 18 is an enlarged view of a portion of the web shown in FIG. 17.

FIG. 19 is a photomicrograph of a portion of a web of the presentinvention.

FIG. 20 is an enlarged view of a portion of a web of the presentinvention.

FIG. 21 is a simplified schematic illustration of a process for making aweb of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 1 is an enlarged, partially segmented perspective illustration of aprior art macroscopically-expanded, three-dimensional, fluid perviouspolymeric web 40 formed generally in accordance with the aforementionedU.S. Pat. No. 4,342,314. Webs of this type have been found to be highlysuitable for use as a topsheet in absorbent articles such as sanitarynapkins, pantyliners, interiabial devices, and the like. The fluidpervious web 40 exhibits a plurality of macroscopic surface aberrationsthat can be apertures, such as primary apertures 41. Primary apertures41 are formed by a multiplicity of interconnecting members, such asfiber like elements, e.g., 42, 43, 44, 45 and 46, that areinterconnected to one another to define a continuous first surface 50 ofthe web 40. Each fiber like element has a base portion, e.g., baseportion 51, located in plane 52 of first surface 50. Each base portionhas a sidewall portion, e.g., sidewall portion 53, attached to eachlongitudinal edge thereof. The sidewall portions extend generally in thedirection of a discontinuous second surface 55 of web 40. Theintersecting sidewall portions are interconnected to one anotherintermediate the first and second surfaces of the web, and terminatesubstantially concurrently with one another in the plane 56 of thesecond surface 55. In some embodiments, the base portion 51 may havesurface aberrations 58 in accordance with the aforementioned Ahr '045patent.

As used herein, the term “macroscopically expanded” refers to thestructure of a web formed from a precursor web or film, e.g., a planarweb, that has been caused to conform to the surface of athree-dimensional forming structure so that both sides, or surfaces, ofthe precursor web are permanently altered due to at least partialconformance of the precursor web to the three-dimensional pattern of theforming structure. Such macroscopically-expanded webs are typicallycaused to conform to the surface of the forming structure by embossing(i.e., when the forming structure exhibits a pattern comprised primarilyof male projections), by debossing (i.e., when the forming structureexhibits a pattern comprised primarily of female depressions, orapertures), or by a combination of both.

As used herein, the term “macroscopic” refers to structural features orelements that are readily visible and distinctly discernable to a humanhaving 20/20 vision when the perpendicular distance between the viewer'seye and the web is about 12 inches. Conversely, the term “microscopic”is utilized to refer to structural features or elements that are notreadily visible and distinctly discernable to a human having 20/20vision when the perpendicular distance between the viewer's eye and theplane of the web is about 12 inches. In general, as used herein, theprimary apertures of a web disclosed herein are macroscopic, and surfaceaberrations, such as hair-like fibrils as disclosed more fully below areconsidered microscopic.

The term “planar” as used herein to refers to the overall condition of aprecursor web or film when viewed by the naked eye on a macroscopicscale, prior to permanently deforming the web into a three-dimensionalformed film. In this context, extruded films prior to post-extrusionprocessing and films that do not exhibit significant degree of permanentmacroscopic three-dimensionality, e.g., deformation out of the plane ofthe film, would generally be described as planar.

As utilized herein, the term “interconnecting members” refers to some orall of the elements of a web, e.g., web 40 in FIG. 1, portions of whichserve to define the primary apertures by a continuous network. As can beappreciated from the description of FIG. 1 and the present inventionherein, the interconnecting members, e.g., fiber like elements 42, 43,44, 45, and 46, are inherently continuous, with contiguousinterconnecting elements blending into one another in mutually adjoiningtransition portions. Individual interconnecting members can be bestdescribed with reference to FIG. 1 as those portions of the web disposedbetween any two adjacent primary apertures, originating in the firstsurface and extending into the second surface. On the first surface ofthe web the interconnecting members collectively form a continuousnetwork, or pattern, the continuous network of interconnecting membersdefining the primary apertures, and on the second surface of the webinterconnecting sidewalls of the interconnecting members collectivelyform a discontinuous pattern of secondary apertures. Interconnectingmembers are described more generally below with reference to FIG. 6.

In a three-dimensional, macroscopically-expanded web, theinterconnecting members may be described as channel-like. Their twodimensional cross-section may also be described as “U-shaped”, as in theaforementioned Radel '314 patent, or “upwardly concave-shaped”, asdisclosed in U.S. Pat. No. 5,514,105, issued on May 7, 1996 to Goodman,Jr., et al. “Upwardly-concave-shaped” as used herein, and as representedin FIG. 1, describes the orientation of the channel-like shape of theinterconnecting members with relation to the surfaces of the web, with abase portion 51 generally in the first surface 50, and the legs, e.g.,sidewall portions 53, of the channel extending from the base portion 51in the direction of the second surface 55, with the channel openingbeing substantially in the second surface 55. In general, for a planecutting through the web, e.g., web 40, orthogonal to the plane, e.g.,plane 52, of the first surface 50 and intersecting any two adjacentprimary apertures, e.g., apertures 41, the resulting cross-section of aninterconnecting member disposed therein will exhibit a generallyupwardly concave shape that may be substantially U-shaped.

The term “continuous” when used herein to describe the first surface ofa macroscopically-expanded, three-dimensional formed film web, refers tothe uninterrupted character of the first surface generally in the planeof the first surface. Thus, any point on the first surface can bereached from any other point on the first surface without substantiallyleaving the first surface. Conversely, as utilized herein, the term“discontinuous” when used to describe the second surface of athree-dimensionally formed film web refers to the interrupted characterof the second surface generally in the plane of the second surface.Thus, any point on the second surface cannot necessarily be reached fromany other point on the second surface without substantially leaving thesecond surface in the plane of the second surface.

FIG. 2 shows an enlarged, partially segmented, perspective illustrationof a portion of another prior art polymeric microapertured web 110formed generally in accordance with the aforementioned Curro '643patent. The microapertured surface aberrations 120 can be formed by ahydroforming process in which a high-pressure liquid jet is utilized toforce the web to conform to a three-dimensional support member. Asshown, ruptures which coincide substantially with the maximum amplitudeof each micropertured surface aberration 120 result in the formation ofa volcano-shaped aperture 125 having relatively thin, irregularly shapedpetals 126 about its periphery. The relatively thin, petal-shaped edgesof the aperture of such a web provide for increased softness impressionon the skin of a user when compared, for example, to the web of Ahr'045. It is believed that this softness impression is due to therelative lack of resistance to compression and shear afforded by thesurface aberrations having volcano-shaped apertures.

As mentioned above, although the microapertured film of Curro '643imparts a superior tactile impression of softness, it can also permitundesirable rewet when used as a topsheet on a disposable absorbentarticle. The web of the present invention solves this problem byproviding for softness via surface aberrations that exhibit lowresistance to compression and shear, comparable to the web of Curro'643, and yet do not permit fluid flow via microapertures. Therefore,one benefit of the web of the present invention is superior softnesstogether with minimal rewet when used as a topsheet on a disposableabsorbent article, such as a sanitary napkin.

FIG. 3 is an enlarged, partially segmented perspective illustration of afluid pervious, macroscopically-expanded, three-dimensional polymericweb 80 of the present invention. The geometric configuration of themacroscopic surface aberrations, e.g., primary apertures 71, of thepolymeric web can be generally similar to that of the prior art web 40illustrated in FIG. 1. Primary apertures 71 may be referred to as“apertures” or “macroapertures” herein, and refer to openings in the webthat permit fluid communication between a first surface 90 of web 80 anda second surface 85 of web 80. The primary apertures 71 of the web shownin FIG. 3 are defined in the plane 102 of first surface 90 by acontinuous network of interconnecting members, e.g., members 91, 92, 93,94, and 95 interconnected to one another. The shape of primary apertures71 as projected in the plane of the first surface 90 may be in the shapeof polygons, e.g., squares, hexagons, etc., in an ordered or randompattern. In a preferred embodiment primary apertures 71 are in the shapeof modified ovals, and in one embodiment primary apertures 71 are in thegeneral shape of a tear drop. Polymer web 80 exhibits a plurality ofsurface aberrations 220 in the form of hair-like fibrils 225, describedmore fully below.

In a three-dimensional, microapertured polymeric web 80 of the presentinvention, each interconnecting member comprises a base portion, e.g.,base portion 81, located generally in plane 102, and each base portionhas sidewall portions, e.g., sidewall portions 83 extending from eachlongitudinal edge thereof. Sidewall portions 83 extend generally in thedirection of the second surface 85 of the web 80 and join to sidewallsof adjoining interconnecting members intermediate the first and secondsurfaces, 90 and 85, respectively, and terminate substantiallyconcurrently with one another to define secondary apertures, e.g.,secondary apertures 72 in the plane 106 of second surface 85.

FIG. 6 is a plan view of representative primary aperture shapesprojected in the plane of the first surface of an alternative embodimentof a three-dimensional, macroapertured polymer web of the presentinvention. While a repeating pattern of uniform shapes, for example atessellating pattern, is preferred, the shape of primary apertures,e.g., apertures 71, may be generally circular, polygonal, or mixed, andmay be arrayed in an ordered pattern or in a random pattern.

As shown in FIG. 6 the interconnecting members, e.g., interconnectingmembers 97 and 98, are each inherently continuous, with contiguousinterconnecting elements blending into one another in mutually adjoiningtransition zones or portions, e.g., portions 87. In general transitionportions are defined by the largest circle that can be inscribed tangentto any three adjacent apertures. It is understood that for certainpatterns of apertures the inscribed circle of the transition portionsmay be tangent to more than three adjacent apertures. For illustrativepurposes, interconnecting members may be thought of as beginning orending substantially at the centers of the transition portions, such asinterconnecting members 97 and 98. Interconnecting members need not belinear, but may be curvilinear. The sidewalls of the interconnectingmembers can be described as interconnecting to the sidewalls ofadjacent, contiguous interconnecting members. Exclusive of portions ofthe transition zones and portions including hair-like fibrils, asdisclosed below, cross-sections of interconnecting members transverse tothe longitudinal centerline between the beginning and end of theinterconnecting member may be generally described as U-shape. However,the transverse cross-section need not be uniform or U-shaped along theentire length of the interconnecting member, and for certain primaryaperture configurations it may not be uniform along most of its length.In particular, in transition zones or portions interconnecting membersblend into contiguous interconnecting members and transversecross-sections in the transition zones or portions may exhibitsubstantially non-uniform U-shapes, or no discernible U-shape.

FIG. 4 is a further enlarged, partial view of the three-dimensionalpolymeric web 80 shown in FIG. 3. The three-dimensional polymeric web 80comprises a polymer film 120, i.e., the precursor film, which can be asingle layer of extruded polymer or a multilayer coextruded or laminatefilm. As shown in FIG. 4, film 120 is a two layer laminate comprising afirst layer 101 and a second layer 103. Laminate materials may becoextruded, as is known in the art for making laminate films, includingfilms comprising skin layers. While it is presently preferred that, asshown in FIG. 4, the polymeric layers, e.g., layers 101 and 103,terminate substantially concurrently in the plane of the second surface106 it is not presently believed to be essential that they do so. One ormore layers may extend further toward the second surface than theother(s).

FIG. 4 shows a plurality of surface aberrations 220 in the form ofhair-like fibrils 225. The hair-like fibrils are formed as protrudedextensions of the polymeric web 80, generally on the first surface 90thereof. The number, size, and distribution of hair-like fibrils 225 onpolymeric web 80 can be predetermined based on desired skin feel. Forapplications as a topsheet in disposable absorbent articles, it ispreferred that hair-like fibrils 225 protrude only from the base portion81 in first surface 90 of polymeric web 80, as shown in FIGS. 3 and 4.Therefore, when web 80 is used as a topsheet in a disposable absorbentarticle, the web can be oriented such that the hair-like fibrils 225 areskin contacting for superior softness impression, and yet, the hair-likefibrils 225 do not obstruct fluid flow through macroapertures 71.Moreover, having hair-like fibrils 225 with closed distal portions 226results in reduced rewet, i.e., reduced amounts of fluid beingre-introduced to the surface of the topsheet after having been firstpassed through the topsheet to underlying absorbent layers.

As shown in cross-section FIG. 5, hair-like fibrils 225 can be describedas protruding from first surface 90 of web 80. As such, hair-likefibrils 225 can be described as being integral with film 120, and formedby permanent local plastic deformation of film 120. Hair-like fibrilscan be described as having a side wall 227 defining an open proximalportion 229 and a closed distal portion 226. Hair-like fibrils 225 havea height h measured from a minimum amplitude A_(min) between adjacentfibrils to a maximum amplitude A_(max) at the closed distal portion 226.Hair-like fibrils have a diameter d, which for a generally cylindricalstructure is the outside diameter at a lateral cross-section. By“lateral” is meant generally parallel to the plane of the first surface102. For non-uniform lateral cross-sections, and/or non-cylindricalstructures of hair-like fibrils, diameter d is measured as the averagelateral cross-sectional dimension at ½ the height h of the fibril, asshown in FIG. 5. Thus, for each hair-like fibril 225, an aspect ratio,defined as h/d, can be determined. Hair-like fibrils 225 can have anaspect ratio h/d of at least 0.5. The aspect ratio can be 1, or 1.5 andis preferably at least about 2.

In general, because the actual height h of any individual hair-likefibril 225 can be difficult to determine, and because the actual heightmay vary, an average height h_(avg) of a plurality of hair-like fibrilscan be determined by determining an average minimum amplitude A_(min)and an average maximum amplitude A_(max) over a predetermined area ofweb 80. Likewise, for varying cross-sectional dimensions, an averagedimension d_(avg) can be determined for a plurality of hair-like fibrils225. Such amplitude and other dimensional measurements can be made byany method known in the art, such as by computer aided scanningmicroscopy and data processing. Therefore, an average aspect ratioAR_(avg) of the hair-like fibrils 225 for a predetermined portion of theweb can be expressed as h_(avg/)/d_(avg.)

The dimensions h and d for hair-like fibrils 225 can be indirectlydetermined based on the known dimensions of a forming structure, asdisclosed more fully below. For example, for a forming structure madeaccording to predetermined dimensions of male protrusions, e.g.,protrusions 2250 shown in FIG. 11 below, on which hair-like fibrils 225are to be formed can have known dimensions. If precursor film 120 isfully and permanently deformed over protrusions 2250, then h and d canbe calculated from these known dimensions, taking into account thethickness of the precursor film 120, including predicted and/or observedweb thinning. If the precursor film 120 is not fully formed overprotrusions 2250, then the height h of hair-like pillars will be lessthan the corresponding height of the protrusions 2250.

In one embodiment the diameter of hair-like fibrils 225 is constant ordecreases with increasing amplitude (amplitude increases to a maximum atclosed distal end 226). As shown in FIG. 5, for example, the diameter,or average lateral cross-sectional dimension, of hair-like fibrils 225can be a maximum at proximal portion 229 and the lateral cross-sectionaldimension steadily decreases to distal end 226. This structure isbelieved to be necessary to ensure the polymeric web 80 can be readilyremoved from the forming structure 350, as more fully described belowwith respect to FIG. 10.

As shown in FIG. 5, some thinning of precursor web 120 can occur due tothe relatively deep drawing required to form high aspect ratio hair-likefibrils 225. For example, thinning can be observed at or near closeddistal ends 226. By “observed” is meant that the thinning is distinctwhen viewed in magnified cross-section. Such thinning can be beneficialas the thinned portions offer little resistance to compression or shearwhen touched by a person's skin. For example, when a person touches thepolymeric web 80 on the side exhibiting hair-like fibrils 225, thefinger tips first contact closed distal ends 226 of hair-like fibrils225. Due to the high aspect ratio of hair-like fibrils 225, and, it isbelieved, to the wall thinning of the film at or near the distal ends226, the hair-like fibrils offer little resistance to the compression orshear imposed on the web by the person's fingers. This lack ofresistance is registered as a feeling of softness, much like the feelingof a velour fabric. In fact, it has been found that polymeric webs ofthe present invention can provide for a feeling of softness equal to orgreater than that of prior art polymeric webs, such as the web disclosedin Curro '643.

It should be noted that a fluid impermeable web having only thehair-like fibrils as disclosed herein, and not having macroscopicapertures, can offer softness for any application in which fluidpermeability is not required. Thus, in one embodiment of the presentinvention, the invention can be described as a polymeric web 80exhibiting a soft and silky tactile impression on at least one surfacethereof, the silky feeling surface of the web 80 exhibiting a pattern ofdiscrete hair-like fibrils 225, each of the hair-like fibrils 225 beinga protruded extension of the web surface and having a side wall 227defining an open proximal portion 229 and a closed distal portion 226,the hair-like fibrils maximum lateral cross-sectional dimension at ornear said open proximal portion, exhibiting a cross-sectional diameter dof between about 50 microns (about 0.002 inch) to about 76 microns(about 0.003 inch), and can be at least 100 microns (0.004 inches) 130microns (0.005 inches). The hair-like fibrils can have an aspect ratiofrom 0.5 to 3.

For disposable absorbent articles, where a topsheet having a fluidpermeable, three-dimensional structure is desired, the invention can bedescribed as a polymeric web 80 exhibiting a soft and silky tactileimpression on at least one surface 90 thereof, the silky feeling surface90 of the web exhibiting a pattern of discrete hair-like fibrils 225,each of the hair-like fibrils 225 being a protruded extension of the websurface 90 and having a side wall 227 defining an open proximal portion229 and a closed distal portion 226, the hair-like fibrils exhibiting anaverage cross-sectional diameter d of between 50 microns (0.002 inches)130 microns (0.005 inches), and an aspect ratio from at least 0.5, 1,1.5, 2, or 3 and wherein the web 80 further exhibits a macroscopicallyexpanded, three-dimensional pattern of macroscopic surface aberrations,e.g., primary apertures 71 superposed thereon, the macroscopic surfaceaberrations 71 being oppositely oriented from the hair-like fibrils 225,that is, the primary apertures extend from a first surface 90 to asecond surface 85 of polymeric web 80.

The “area density” of the hair-like fibrils 225, which is the number ofhair-like fibrils 225 per unit area of first surface 90, can beoptimized for use in absorbent articles. In general, thecenter-to-center spacing can be optimized for adequate tactileimpression, while at the same time minimizing fiber-to-fiber entrapmentof fluid. Currently, it is believed that a center-to-center spacing ofabout 100 microns to 250 microns (about 0.004 inch to about 0.010 inch)is optimal for use in sanitary napkins. Minimizing entrapment of mensesbetween fibers improves the surface cleanliness of the sanitary napkin,which, in turn improves the cleanliness and skin health of the wearer.

In one embodiment, “superposed thereon” means that the polymeric webappears generally as shown in FIG. 3, wherein the pattern of discretehair-like fibrils 225 is disposed on the land areas 81 of theinterconnecting members only, i.e., only on the first surface 90 of web80. However, conceptually, it is contemplated that “superposed thereon”could also cover an embodiment (not shown) in which the pattern ofdiscrete hair-like fibrils 225 extends into macroapertures 71, forexample on side walls 83 of the interconnecting members. In otherembodiments, hair-like fibrils 225 are disposed only in certainpredetermined regions of web 80. For example, a topsheet for a sanitarynapkin can have a central region having hair-like fibrils 225, and theremainder of the topsheet being free from hair-like fibrils 225.

Precursor web 120 can be any polymeric film having sufficient materialproperties to be formed into the web of the present invention by thehydroforming process described herein. That is, precursor web 120 musthave sufficient yield properties such that the precursor web 120 can bestrained without rupture to an extent to produce hair-like fibrils 225and, in the case of a three-dimensional, macroscopically-apertured,formed film, rupture to form macroapertures 71. As disclosed more fullybelow, process conditions such as temperature can be varied for a givenpolymer to permit it to stretch with or without rupture to form the webof the present invention. In general, therefore, it has been found thatpreferred starting materials to be used as the precursor web 120 forproducing the web 80 of the present invention exhibit a low yield andhigh-elongation characteristics. In addition, the starting filmspreferably strain harden. Examples of films suitable for use as theprecursor web 120 in the present invention include films of low densitypolyethylene (LDPE), linear low-density polyethylene (LLDPE), andblendsof linear low-density polyethylene and low density polyethylene(LDPE/LLDPE).

Precursor web 120 must also be sufficiently deformable and havesufficient ductility for use as a polymeric web of the presentinvention. The term “deformable” as used herein describes a materialwhich, when stretched beyond its elastic limit, will substantiallyretain its newly formed conformation.

One material found suitable for use as a precursor web 120 of thepresent invention is DOWLEX 2045A polyethylene resin, available from TheDow Chemical Company, Midland, Mich., USA. A film of this materialhaving a thickness of 20 microns can have a tensile yield of at least 12MPa; an ultimate tensile of at least 53 MPa; an ultimate elongation ofat least 635%; and a tensile modulus (2% Secant) of at least 210 MPa(each of the above measures determined according to ASTM D 882).

Precursor web 120 can be a laminate of two or more webs, and can be aco-extruded laminate. For example, precursor web 120 can comprise twolayers as shown in FIG. 4, and precursor web 120 can comprise threelayers, wherein the inner most layer is referred to as a core layer, andthe two outermost layers are referred to as skin layers. In oneembodiment precursor web 120 comprises a three layer coextruded laminatehaving an overall thickness of about 25 microns (0.001 in.), with thecore layer having a thickness of about 18 microns (0.0007 in.); and eachskin layer having a thickness of about 3.5 microns (0.00015 in.). Ingeneral, for use as a topsheet in sanitary napkins, precursor web 120should have an overall thickness (sometimes referred to as caliper) ofat least about 10 microns and less than about 100 microns. The thicknessof precursor web 120 can be about 15 microns, 20 microns, 25 microns, 30microns, 35 microns, 40 microns, 45 microns, or 60 microns. In general,the ability to form high area density (or low average center-to-centerspacing C) hair-like fibrils 225 on web 80 is limited by the thicknessof precursor web 120. For example, it is believed that thecenter-to-center spacing C of two adjacent hair-like fibrils 225 shouldbe greater than twice the thickness of precursor web 120 to permitadequate and complete three-dimensional web formation between adjacentprotrusions 2250 of forming structure 350 as disclosed more fully below.

The precursor web 120 preferably comprises a surfactant. In a threelayer laminate, the core layer can comprise a surfactant while the outerlayers are initially devoid of surfactants. Preferred surfactantsinclude those from non-ionic families such as: alcohol ethoxylates,alkylphenol ethoxylates, carboxylic acid esters, glycerol esters,polyoxyethylene esters of fatty acids, polyoxyethylene esters ofaliphatic carboxylic acids related to abietic acid, anhydrosorbitolesters, etyhoxylated anhydrosorbitol esters, ethoxylated natural fats,oils, and waxes, glycol esters of fatty acids, carboxylic amides,diethanolamine condensates, and polyalkyleneoxide block copolymers.Molecular weights of surfactants selected for the present invention mayrange from about 200 grams per mole to about 10,000 grams per mole.Preferred surfactants have a molecular weight from about 300 to about1,000 grams per mole.

The surfactant level initially blended into precursor web 120 (oroptionally the core layer in a three layer laminate) can be as much as10 percent by weight of the total multilayer structure. Surfactants inthe preferred molecular weight range (300-1,000 grams/mole) can be addedat lower levels, generally at or below about 5 weight percent of thetotal multilayer structure.

The precursor web 120 can also comprise titanium dioxide in the polymerblend. Titanium dioxide can provide for greater opacity of the finishedweb 80. Titanium dioxide can be added at up to about 10 percent byweight to low density polyethylene for blending into the precursor web120 material.

Other additives, such as particulate material, e.g., calcium carbonate(CaCO₃), particulate skin treatments or protectants, or odor-absorbingactives, e.g., zeolites, can be added in one or more layers of precursorweb 120. In some embodiments, webs 80 comprising particulate matter,when used in skin-contacting applications, can permit actives to contactthe skin in a very direct and efficient manner. Specifically, in someembodiments, formation of hair-like fibrils 225 can expose particulatematter at or near the distal ends thereof. Therefore, actives such asskin care agents can be localized at or near distal ends 226 to permitdirect skin contact with such skin care agents when the web 80 is usedin skin contacting applications.

The precursor web 120 can be processed using conventional procedures forproducing multilayer films on conventional coextruded film-makingequipment. Where layers comprising blends are required, pellets of theabove described components can be first dry blended and then melt mixedin the extruder feeding that layer. Alternatively, if insufficientmixing occurs in the extruder, the pellets can be first dry blended andthen melt mixed in a pre-compounding extruder followed byrepelletization prior to film extrusion. Suitable methods for makingprecursor web 120 are disclosed in U.S. Pat. No. 5,520,875, issued toWnuk et al. on May 28, 1996 and U.S. Pat. No. 6,228,462, issued to Leeet al. on May 8, 2001; both patents the disclosure of which isincorporated herein by reference.

A fluid pervious polymeric web of the present invention can be utilizedas a topsheet on a catamenial device, such as a sanitary napkin. Forexample, a polymeric web 80 of the present invention exhibiting amacroscopically expanded, three-dimensional pattern of macroscopicsurface aberrations in the form of primary apertures 71 combinessoftness properties with excellent fluid rewet properties (i.e., reducedfluid rewet compared to previous webs, such as the web of Curro '643).

FIG. 7 is a top plan view of a sanitary napkin 20 with portions cut awayto more clearly show the construction of the napkin 20, includingtopsheet 22, which can comprise a polymeric web 80 of the presentinvention. It should be understood that the polymeric web 80 of thepresent invention can also be utilized in other absorbent articles suchas pantyliners, interlabial devices, diapers, training pants,incontinent devices, wound dressings and the like. It also should beunderstood, that the present invention is not limited to the particulartype or configuration of the sanitary napkin 20 shown in FIG. 7, whichis simply a representative non-limiting example.

As shown in FIG. 8, the sanitary napkin 20 has two surfaces, abody-facing surface 20 a and an opposed garment-facing surface 20 b. Thebody-facing surface 20 a is intended to be worn adjacent to the body ofthe wearer. The garment-facing surface 20 b is intended to be placedadjacent to the wearer's undergarments when the sanitary napkin 20 isworn.

The sanitary napkin 20 has two centerlines, a longitudinal centerline“l” and a transverse centerline “t”. The term “longitudinal”, as usedherein, refers to a line, axis or direction in the plane of the sanitarynapkin 20 that is generally aligned with (e.g., approximately parallelto) a vertical plane which bisects a standing wearer into left and rightbody halves when the sanitary napkin 20 is worn. The terms “transverse”or “lateral” as used herein, are interchangeable, and refer to a line,axis or direction which lies within the plane of the sanitary napkin 20that is generally perpendicular to the longitudinal direction.

As shown in FIG. 7, the sanitary napkin 20 comprises a liquid pervioustopsheet 22, which can comprise web 80 of the present invention, aliquid impervious backsheet 23 joined with the liquid pervious topsheet22, and an absorbent core 24 positioned between the liquid pervioustopsheet 22 and the liquid impervious backsheet 23. FIG. 7 also showsthat the sanitary napkin 20 has a periphery 30 which is defined by theouter edges of the sanitary napkin 20 in which the longitudinal edges(or “side edges”) are designated 31 and the end edges (or “ends”) aredesignated 32.

Sanitary napkin 20 preferably includes optional sideflaps or “wings” 34that can be folded around the crotch portion of the wearer's panties.The side flaps 34 can serve a number of purposes, including, but notlimited to protecting the wearer's panties from soiling and keeping thesanitary napkin secured to the wearer's panties.

FIG. 8 is a cross-sectional view of the sanitary napkin taken alongsection line 8-8 of FIG. 7. As can be seen in FIG. 8, the sanitarynapkin 20 preferably includes adhesive fastening means 36 for attachingthe sanitary napkin 20 to the undergarment of the wearer. Removablerelease liners 37 cover the adhesive fastening means 36 to keep theadhesive from sticking to a surface other than the crotch portion of theundergarment prior to use. In addition to having a longitudinaldirection and a transverse direction, the sanitary napkin 20 also has a“z” direction or axis, which is the direction proceeding down throughthe liquid pervious topsheet 22 and into whatever fluid storage core 24that may be provided. A continuous path between the liquid pervioustopsheet 22 and underlying layer or layers of the articles hereinpermits fluid to be drawn in the “z” direction and away from thetopsheet of the article into its ultimate storage layer. In someembodiments, the continuous path will have a gradient of increasingcapillary attraction, which facilitates fluid flow down into the storagemedium.

In FIG. 9 there is shown single-phase web process for debossing anddrying a continuous polymeric web 80 of the present invention. Bysingle-phase is meant that the process uses only one three-dimensionalforming structure. By continuous is meant to distinguish the describedprocess from a batch process in which individual, discrete samples ofweb are made, often referred to as hand sheets. While it is recognizedthat webs of the present invention can be batch-processed using thestructures described for the continuous process, a continuous process isthe preferred method for commercially making a polymeric web of thepresent invention. Further, while the process described with respect toFIG. 9 is primarily designed to form macroscopically-expanded webshaving hair-like fibrils 225 and primary apertures, e.g., apertures 71of web 80, it is believed that a hydroforming process can be utilized toform a web having only hair-like fibrils by suitably modifying theforming structure to have only protrusions 2250.

Polymeric web 80 of the present invention can be formed by ahydroforming process on a single three-dimensional forming structure 350and can also be annealed and/or dried on the forming structure 350 priorto rewinding the web into roll stock for further processing. Thethree-dimensional structures of a polymeric web, e.g., polymeric web 80shown in FIG. 4, are formed by forcing the web to conform to the formingstructure 350, which rotates about stationary forming drum 518. Formingstructure 350 is described more fully below, but, in general, it is athree-dimensional form to which the precursor web 120 is forced toconform.

Precursor web 120 can be extruded and chilled immediately prior to beingfed directly onto the surface of forming structure 350, or it can be fedfrom a supply roll, as shown by supply roll 501 in FIG. 9. In someembodiments it is preferred that the temperature of the precursor web120 be elevated sufficiently to soften it and make it more conformableto the forming structure 350. The temperature of precursor web 120 canbe elevated by applying hot air or steam to the web or by passing theweb through heated nip rolls, prior to subjecting it to the formingprocess.

In the process described in FIG. 9, precursor web 120 is fed in asubstantially planar condition in the machine direction (MD) from asupply roll 501 onto the surface of forming structure 350. Formingstructure 350 rotates at a speed such that the tangential surfacevelocity of the forming structure 350 substantially matches that of thelinear velocity of precursor web 120 in the machine direction, so thatduring the hydroforming process the web is substantially stationaryrelative to forming structure 350.

Once precursor web 120 is adjacent to and being “carried on”, so tospeak, the forming structure 350, precursor web 120 is directed overstationary vacuum chamber 520 which is interior to forming drum 518.Although the hydroforming process described herein can be accomplishedto some degree without vacuum chambers, in general, vacuum chambers aidin better three-dimensional web formation as well as liquid removal. Asprecursor web 120 passes over vacuum chamber 520, the outwardly-exposedsurface of precursor web 120 is impinged upon by a liquid jet 540discharged from high pressure liquid jet nozzle 535 between a pair ofstationary liquid baffles 525 and 530 which served to help localizesplashing liquid. The effect of the liquid jet 540 is to cause theprecursor web to conform to forming structure 350. As precursor webconforms to forming structure 350, both the hair-like fibrils 225 andthe primary apertures 71 can be formed. As primary apertures 71 form,vacuum from vacuum chamber 520 aids in removing excess liquid from theweb, and, in some cases aids in forming precursor web 120 to formingstructure 350. As precursor web 120 is passed under the influence ofhigh pressure liquid jet 540, it is permanently deformed to conform tothe forming structure 350, thereby being formed into three-dimensional,macroscopically-expanded polymeric web 80 of the present invention.

In the process described with reference to FIG. 9, a single liquid jet540 is described as forming both the hair-like fibrils 225 and theprimary apertures 71. In another embodiment, additional liquid (orfluid) jets can be used to form the three-dimensional web structures inmultiple stages. For example, a first fluid, such as water, can impingeprecursor web 120 to form macroapertures 71 in a first stage, andfollowing the first stage, a second fluid, such as hot water or air(optionally in combination with a vacuum chamber) can impinge thepartially-formed web to form the hair-like fibrils 225 in a secondstage.

In general, therefore, more than one fluid (e.g., water, air) can bedirected to impinge on, and do energetic work on, precursor web 120 instages. It is believed that, for thermoplastic precursor webs 120, asthe temperature of the precursor web approaches its melting point, itmore easily stretches without rupture to form over protrusions 2250 offorming structure 350. However, for forming macroapertures it is moredesirable to have relatively high strain rates and relatively rapidrupture, and for forming hair-like fibrils it is more desirable to haverelatively low strain rates and no rupture. Accordingly, in a two-stageforming process, the temperature of the impinging fluid at first and/orsecond stages can be adjusted independently, depending on the dwell timeover which each impingement acts and the temperature of the precursorweb 120 to form both macroapertures 71 and high aspect ratio hair-likefibrils 225 independently.

For making webs suitable for use as a topsheet in a disposable absorbentarticle, precursor web 120 can be a polyolefinic film from about 10microns to about 100 microns in total thickness. For such precursor webs120, high pressure liquid jet 540 is typically water at a temperaturefrom about 15-95 degrees C., operated at a pressure in the range ofabout 200 psig to about 1200 psig and a water flow rate in the range ofabout 18 liters (4 gallons) per minute to about 62 liters (14 gallons)per minute per 25.4 cross-machine direction (CD) mm (1 inch) of width ofthe precursor web 120.

After passing beyond the high pressure liquid jet 540, (or jets, asdiscussed above), polymeric web 80 of the present invention can be driedwhile still on forming structure 350. For example, as shown in FIG. 9,polymeric web 80 can be directed, while still on forming structure 350,under the influence of drying means 590. Drying means 590 can be any ofmeans for removing, or driving off liquids from polymeric webs, such asradiant heat drying, convective drying, ultrasonic drying, high velocityair knife drying, and the like. In general, a drying medium 600 can beutilized, such as heated air, ultrasonic waves, and the like. Astationary vacuum chamber 555 can be utilized to aid in drying by meansof a partial pressure inside forming drum 518. Drying means 590 can bedesigned to drive liquid off of polymeric web 80 and into vacuum chamber555. Baffles 570 and 580 can be utilized to locally contain any liquidthat gets removed and does not enter vacuum chamber 555. Baffles 570 and580 can also serve to localize and direct heat or heated air used fordrying.

Using a heated drying medium 600 has an additional benefit for makingwebs 80 of the present invention. Prior art macroscopically-expanded,three-dimensional polymeric webs, such as the webs disclosed in Curro'643, are dried in a separate process after being removed form theirrespective forming structures. These webs are typically wound onto aroll for storage until needed for web processing of disposable articles,for example. One problem associated with prior art webs is thecompression setting that occurs during winding and storage. Withoutbeing bound by theory, it is believed that three-dimensionalpolyethylene webs can experience a secondary crystallization over timewhich “locks in” the collapsed, wound state of the web. It has beenfound that by first annealing three-dimensional polymeric webs bysubjecting them to elevated temperatures for a sufficient time, thisobserved compression set is reduced or prevented altogether. In general,however, it is difficult to subject prior art webs to the requisitetemperatures due to the relatively fragile structure. That is, if aprior art web is subjected to annealing temperatures, the web tends tolose the three-dimensional structure formed on the forming structure.For this reason, therefore, drying the web while still on the formingstructure provides a significant processing benefit by permittingprocessing with sufficiently high annealing temperatures to anneal theweb, while at the same time drying it. The annealing temperature willvary depending on the time of drying, the polymer used and the thicknessof the web, but, in general, for polyolefinic webs, a drying/annealingtemperature of between about 50-250 degrees C is sufficient.

After polymeric web 80 passes the drying (or drying/annealing) stage ofthe process it can be removed from the forming structure 350 aboutroller 610 and is thereafter rewound or fed directly to subsequentconverting operations.

A forming structure of the present invention, such as forming structure350 referred to with respect to FIG. 9, is necessary for making a web ofthe present invention. The forming structure is sometimes referred to asa forming screen. FIG. 10 shows a portion of a forming structure of thepresent invention 350 in partial perspective view. The forming structure350 exhibits a plurality of forming structure apertures 710 defined byforming structure interconnecting members 910. Forming structureapertures 710 permit fluid communication between opposing surfaces, thatis, between forming structure first surface 900 in the plane of thefirst surface 1020 and forming structure second surface 850 in the planeof the second surface 1060. Forming structure sidewall portions 830extend generally between the forming structure first surface 900 andforming structure second surface 850. Protrusions 2200 extend fromforming structure first surface 900 to form generally columnar,pillar-like forms.

A comparison of FIG. 10 with FIG. 3 shows the general correspondence offorming structure 350 with polymeric web 80 of the present invention.That is, the three-dimensional protrusions 2250 and depressions (e.g.,apertures 710) of forming structure 350 have a one-to-one correspondenceto the hair-like fibrils 225 and primary apertures 71, respectively, ofpolymeric web 80. The one-to-one correspondence is necessary to theextent that the forming structure 350 determines the overall dimensionsof the polymeric web 80 of the present invention. However, the distancebetween plane of the first surface 102 and plane of the second surface106 of the polymeric web 80 need not be the same as the distance betweenthe plane of the first surface 1020 and the plane of the second surface1060 of forming structure 350. This is because the distance “T” forpolymeric web 80, as shown in FIG. 5, is not dependent upon the actualthickness of forming structure 350, the thickness being theperpendicular distance between the plane of the first surface 1020 andthe plane of the second surface 1060 of forming structure 350.

FIG. 11 is a further enlarged, partial perspective view of the formingstructure 350 shown in FIG. 10, and compares with the similar view ofpolymeric web 80 in FIG. 4. Protrusions 2250 can be made by methodsdescribed below to extend from first surface 900 to a distal end 2260.As shown in the further enlarged view of FIG. 12, protrusions 2250 canhave a height hp measured from a minimum amplitude measured from firstsurface 900 between adjacent protrusions to distal end 2260. Protrusionheight hp can be at least about 50 microns (about 0.002 inch) and can beat least about 76 microns (about 0.003 inch), and can be at least about152 microns (about 0.006 inch), and can be at least about 250 microns(about 0.010 inch), and can be at least about 381 microns (about 0.015inch). Protrusions 2250 have a diameter dp, which for a generallycylindrical structure is the outside diameter. For non-uniformcross-sections, and/or non-cylindrical structures of protrusions 2250,diameter dp is measured as the average cross-sectional dimension ofprotrusions at ½ the height hp of the protrusions 2250, as shown in FIG.12. Protrusion diameter dp can be about 50 microns (about 0.002 inch),and can be at least about 76 microns (about 0.003 inch), and can be atleast about 127 microns (about 0.005 inch). Thus, for each protrusion2250, a protrusion aspect ratio, defined as hp/dp, can be determined.Protrusions 2250 can have an aspect ratio hp/dp of at least 1, and ashigh as 3 or more. The aspect ratio can be at least about 5 and can beabout 6. The protrusions 2250 can have a center-to-center spacing Cpbetween two adjacent protrusions 2250 of between about 100 microns(about 0.004 inch) to about 250 microns (about 0.010 inch). In general,it is believed that the actual distance between two adjacent protrusions2250 (i.e., a “side-to-side” dimension) should be greater than twice thethickness t of precursor web 120 to ensure adequate deformation ofprecursor web 120 between adjacent protrusions 2250.

In general, because the actual height hp of each individual protrusion2250 may vary, an average height hp_(avg) of a plurality of protrusions2250 can be determined by determining a protrusion average minimumamplitude Ap_(min) and a protrusion average maximum amplitude Ap_(max)over a predetermined area of forming structure 350. Likewise, forvarying cross-sectional dimensions, an average protrusion diameterdp_(avg) can be determined for a plurality of protrusions 2250. Suchamplitude and other dimensional measurements can be made by any methodknown in the art, such as by computer aided scanning microscopy andrelated data processing. Therefore, an average aspect ratio of theprotrusions 2250, ARp_(avg) for a predetermined portion of the formingstructure 350 can be expressed as hp_(avg/)/dp_(avg). The dimensions hpand dp for protrusions 2250 can be indirectly determined based on theknown specifications for making forming structure 350, as disclosed morefully below.

In one embodiment the diameter of protrusions 2250 is constant ordecreases with increasing amplitude. As shown in FIG. 12, for example,the diameter, or largest lateral cross-sectional dimension, ofprotrusions 2250 is a maximum near first surface 900 and steadilydecreases to distal end 2260. This structure is believed to be necessaryto ensure that the polymeric web 80 can be readily removed from theforming structure 350.

Forming structure 350 can be made of any material that can be formed tohave protrusions 2250 having the necessary dimensions to make a web ofthe present invention, is dimensionally stable over process temperatureranges experienced by forming structure 350, has a tensile modulus of atleast about 5 MPa, a yield strength of at least about 5 MPa, and astrain at break of at least about 1%, preferably at least about 5%.Dimensional stability is necessary only for commercial processes asdescribed with respect to FIG. 9, because for some process conditionsthe forming structure 350/forming drum 518 interface can be compromisedif the forming structure 350 expands or contracts more than the formingdrum 518. For batch processing of polymeric webs of the presentinvention dimensional stability is not a requirement. Processtemperature ranges are affected by process conditions including thetemperature of the fluid jet, e.g., liquid jet 540, and the temperatureof forming structure 350, which can be heated, for example. In general,for polyolefinic webs, including laminated, co-extruded films for use inwebs for disposable absorbent articles (i.e., films having a thickness,t, of about 10-100 microns), a water temperature of between 15 degrees Cand 95 degrees C can be used. The drying/annealing air temperature canbe 250 degrees C or less. In general, process temperatures can be variedthroughout a wide range and still make the polymeric web 80 of thepresent invention. However, the temperature ranges can be varied to makepolymeric web 80 at optimal rates depending on film thickness, filmtype, and line speed.

In a preferred embodiment, protrusions 2250 are made integrally withforming structure 350. That is, the forming structure is made as anintegrated structure, either by removing material or by building upmaterial. For example, forming structure 350 having the requiredrelatively small scale protrusions 2250 can be made by local selectiveremoval of material, such as by chemical etching, mechanical etching, orby ablating by use of high-energy sources such as electrical-dischargemachines (EDM) or lasers.

A portion of a prototype forming structure 350 made of steel and havingprotrusions 2250 made by a conventional EDM process is shown in FIGS. 13and 14. FIG. 13 is a photomicrograph of a forming structure 350 and FIG.14 is a further enlarged view the forming structure of FIG. 13. As shownin FIG. 13, a steel forming structure has been subjected to an EDMprocess to form integral protrusions 2250 having distal ends 2260. Theforming structure 350 shown in FIGS. 13 and 14 has depressions 710generally similarly shaped to those shown in FIG. 3. However, as can beseen in FIGS. 13 and 14, the structure is less than ideal for makingtopsheets for absorbent articles because of the geometrical constraintsof both the forming structure 350 prior to the EDM process, and the EDMprocess itself Specifically, as can be seen, first surface 900 offorming structure interconnecting members 910 is only one protrusion“wide”. Also, as can be seen in FIG. 13, due to the geometricalconstraints of the process of EDM, gaps between protrusions 2250 canresult. For example, gap 901 in FIG. 13 resulted from the EDM wire beingoriented slightly off parallel from the respective forming structureinterconnecting members 910 shown. Therefore, for commerciallysuccessful production of webs suitable for topsheets in disposableabsorbent articles, the forming structure shown in FIG. 13 may not beacceptable. However, it is clear that suitably shaped protrusions 2250having the required aspect ratios can be formed. The protrusions 2250 ofthe forming structure shown in FIG. 13 have an average height hp_(avg)of about 275 microns (0.011 inch), and an average diameter of aboutdp_(avg) of about 100 microns (0.004 inch), defining an average aspectratio of ARp_(avg) of about 2.7. (Note that the forming screen shown inFIGS. 13 and 14 is a prototype, and has been processed by EDM on bothsides. In practice, it is only necessary to form protrusions on oneside.)

In another method of making forming structure 350, a base materialsusceptible to laser modification is laser “etched” to selectivelyremove material to form protrusions 2250 and forming structure apertures710. By “susceptible to laser modification” means that the material canbe selectively removed by laser light in a controlled manner,recognizing that the wavelength of light used in the laser process, aswell as the power level, may need to be matched to the material (orvice-versa) for optimum results. Currently known materials susceptibleto laser modification include thermoplastics such as polypropylene,acetal resins, thermosets such as crosslinked polyesters, or epoxies, oreven metals such as aluminum or stainless steel. Optionally,thermoplastic and thermoset materials can be filled with particulate orfiber fillers to increase compatibility with lasers of certainwavelengths of light and/or to improve modulus or toughness to make moredurable protrusions 2250.

FIG. 15 is a photomicrograph of laser-etched embodiment of a formingstructure 350 of the present invention. FIG. 16 is an enlarged view ofanother, but similar, forming structure 350 of the present invention.The forming structures 350 shown in FIGS. 15 and 16 are made by firstforming a polymer layer having formed therein depressions 710, which asshown are generally “teardrop” shaped and would make generally teardropshaped primary apertures 71 in web 80 of the present invention. Thepolymer layer having depressions 710 therein can be formed by radiatinga liquid photosensitive resin such as a UV-light-curable polymer,through an appropriate masking layer on an underlying support layer (notshown) such as a foraminous woven backing. Suitable polymer layers,support layers, masking layers and UV-curing processes are well known inthe art of making paper-making belts and are disclosed in U.S. Pat. No.5,334,289 issued to Trokhan et al., on Aug. 2, 1994; and U.S. Pat. No.4,529,480 issued to Trokhan on Jul. 16, 1985; and U.S. Pat. No.6,010,598 issued to Boutilier et al. on Jan. 4, 2000, each of thesepatents, being hereby incorporated herein by reference for the teachingof structures, resins and curing techniques. As disclosed in theBoutilier '598 patent, for example, one suitable liquid photosensitiveresin composition is comprised of four components: a prepolymer;monomers; photoinitiator and antioxidants. A preferred liquidphotosensitive resin is Merigraph L-055 available from MacDermid ImagingTechnology, Inc. of Wilmington, Del.

After the polymer layer is cured to have depressions 701 the polymerlayer is laser etched to form protrusions 2250 having distal ends 2260.Laser etching can be achieved by known laser techniques, selectingwavelength, power, and time parameters as necessary to produce thedesired protrusion dimensions. In the forming structure of FIG. 16,protrusions have an average height hp of 250 microns and an averagediameter dp of 85 microns (at ½ height hp) and an aspect ratio arp ofabout 2.9.

In one embodiment, forming structure 350 formed as a cured polymer on asupport layer can be used as is, with the support layer being a part offorming structure 350. However, in another embodiment, the cured polymercan be removed from the support layer and used alone. In this case, itmay be desirable to only partially cure the polymer, remove the supportlayer 903 and finish fully curing the polymer material.

A web 80 made on the forming structure shown in FIG. 15 is shown in thephotomicrographs of FIGS. 17 and 18. FIG. 17 is a photomicrograph of aportion of web 80 showing hair-like fibrils 225 and aperture 71. FIG. 18is a further enlarged view of web 80 showing in more detail hair-likefibrils 225 having closed distal ends 226. The precursor web 120 for theweb 80 shown in FIGS. 17 and 18 was made from a 25 micron (0.001 inch)thick Dowlex 2045A precursor film 120.

FIGS. 19 and 20 show greatly enlarged portions of webs 80 made in batchprocesses on the forming structure shown in FIGS. 13 and 14 to moreclosely show details of hair-like fibrils 225. The polymer webs 80 shownin FIGS. 19 and 20 have primary apertures 71 (not shown) generally in apentahexagon shape, each having a projected area in the first surface 90of about 1.4 square millimeters. The spacing between primary apertures71 is such that the open area primary apertures 71 as projected in thefirst surface 90 is up to 65% of total surface area. The web 80 exhibitsabout 4,650 hair-like fibrils 225 per square centimeter of first surface90 area (about 30,000 hair-like fibrils 225 per square inch). Thisconcentration of hair-like fibrils 225 is referred to as the “density”or “area density” of hair-like fibrils 225, and represents the number ofhair-like fibrils per unit area of first surface 90, as opposed to totalarea of polymer web 80. Thus, the regions of polymer web 80corresponding to primary apertures 71 do not contribute to the area whencalculating density. In general, the density is determined by theaverage center-to-center spacing of the protrusions 2250 on formingstructure 350, which is about 150 microns (0.006 inch) for the formingstructure shown in FIGS. 13 and 14.

It is believed that a polymer web 80 of the present invention suitablefor use as a topsheet on a disposable absorbent article (e.g., asanitary napkin) should have a density of hair-like fibrils 225 of atleast about 1550 per square centimeter (about 10,000 per square inch).The density of hair-like fibrils 225 can be about 2325 per squarecentimeter (about 15,000 per square inch), and can be about 3100 persquare centimeter (about 20,000 per square inch) and can be about 3875per square centimeter (about 25,000 per square inch). Since for somewebs it may be difficult to determine exactly where first surface 90begins and ends, density can be approximated by taking total area of apredetermined portion of polymer web 80 and subtracting out the area ofprimary apertures 71 as projected in the first surface 90 of thatpredetermined portion. The area of primary apertures 71 can be based onthe projected area of the depressions 710 of forming structure 350. By“projected area” is meant the area of a surface if it were projectedonto a plane parallel to that surface, and can be imagined by analogy,for example, as an “ink stamp” of the surface.

FIG. 19 is a photomicrograph of a web 80 made from a 25 micron (0.001inch) Dowlex 2045A precursor film 120. As shown, the web 80 of FIG. 19comprises discrete hair-like fibrils 225, each of the hair-like fibrils225 being a protruded extension of first surface 90. Each of thehair-like fibrils 225 has a side wall 227 defining an open portion 229(as shown in FIG. 5) and a closed distal portion 226. The hair-likefibrils 225 shown have a height of about 211 microns, and a diameter at½ their height of about 142 microns, resulting in an aspect ratio ofabout 1.5.

The web 80 of FIG. 20 comprises discrete hair-like fibrils 225, each ofthe hair-like fibrils 225 being a protruded extension of first surface90. Each of the hair-like fibrils 225 has a side wall 227 defining anopen portion 229 (as shown in FIG. 5) and a closed distal portion 226.The hair-like fibrils 225 shown in FIG. 20 have an aspect ratio AR of atleast 1.

The difference between the webs 80 shown in FIGS. 19 and 20 is that theprecursor film 120 used to make the polymeric web 80 shown in FIG. 20was a coextruded four layer polyethylene film comprising calciumcarbonate in one of the outermost layers. Specifically, the calciumcarbonate was added into the polymer melt for the polymer that forms thefirst surface of web 80 after formation of hair-like fibrils 225. Thefour layers comprised polyethylene in the follow order: (1) ExxonMobilNTX-137 at about 42 volume percent; (2) ExxonMobil Exact 4151 at about16 volume percent; (3) ExxonMobil Exact 4049 at about 32 volume percent;and (4) a mixture of 57 weight percent Ampacet 10847 with calciumcarbonate blended in as a master batch and 43 weight percent ExxonMobilLD 129, this mixture at a volume percent of about 10 percent. Theprecursor film 120 had a starting thickness of about 25 microns (0.001inch).

One interesting and unexpected result of using a CaCO₃/PE blend for askin layer of precursor film 120 is the formation of regions ofroughened outer surfaces 228 at or near the distal end 226 of hair-likefibrils 225 as can be seen on the web shown in FIG. 20. These regions ofrelatively greater surface roughness 228, which have less surfacesmoothness than the surrounding surfaces, such as first surface 90,provide for a more cloth-like appearance due to its inherent low gloss,and an even greater soft and silky tactile impression. Without beingbound by theory, it is believed that the relatively roughened surfacetexture of the distal ends of hair-like fibrils 225 gives greatertexture that is experienced as softness to the skin of a person touchingthe surface. Without being bound by theory, it is believed that theformation of roughened outer surfaces at or near the distal end 226 ofhair-like fibrils 225 is a result of deep drawing precursor web havingtherein particulate matter. It appears that possibly the particulatematter, in this case CaCO₃, causes stress concentrations in the filmblend that give rise to surface discontinuities. At the points ofmaximum strain, i.e., at the point of maximum draw of hair-like fibrils225, the surface of the film (i.e., precursor film 120) breaks up,exposing particulate matter on the surface of the hair-like fibrils 225.

Therefore, in one embodiment polymer web 80 can be described as havinghair-like fibrils 225 in which at least a portion near the distal end226 thereof exhibits regions of relatively greater surface roughness 228than the remaining portions. By using different additive particulatematter, the regions of relatively greater surface roughness 228 canprovide for other benefits. For example, particulate skin treatments orprotectants or odor-absorbing actives can be used. Importantly, webs 80comprising particulate matter permit actives to be delivered to the skinof a wearer of an article using web 80 in a very direct and efficientmanner.

In general, it is believed that any non-diffusing ingredient(particulate and non-particulate) blended into the melt of a polymer ofprecursor web 120 can be exposed upon strain of the polymer near thedistal end of hair-like fibrils 225. Specifically, actives such as skincare agents can be localized substantially at or near distal ends 226which can be the primary skin contact surfaces for web 80. Other knownmethods of imparting localized strain to polymeric films can also serveto expose non-diffusing ingredients in layers. For example, embossing,ring rolling, thermovacuum forming, and other known processes canprovide for localized rupture and exposure of active ingredients ofpolymer films.

Other methods of making forming structure 350 include building up thestructure by way of localized electroplating, 3-D deposition processes,or photoresist techniques. Photoresist techniques include forming athree dimensional structure by use of an appropriate mask over a liquidphotosensitive resin, such as the UV-curable polymer disclosed above. UVcuring is effective at curing only the portions of a liquid resinexposed to UV light from a UV light source. The remaining (uncured)portions of the liquid resin can then be washed off, leaving behind onlythe cured portions. The liquid resin UV-curable polymer can be placed ona tray, for example, to a desired depth or thickness and appropriatelymasked and UV light-cured to selectively cure the portions to beprotrusions 2250 and to not cure the portions that will be the apertures710. Curing can be done in stages, so that first a negative mask havingUV blocking portions corresponding to forming structure apertures 710(having UV blocking portions in a pattern of teardrops, for example),can be used to first partially cure the polymer by directing a UV lightsource orthogonal to the mask for a sufficient amount of time. Once thepolymer is partially cured in the unmasked areas, a second maskcomprising a plurality of closely spaced UV-transparent spots or dotscan be placed between the light source and the partially cured polymer.The polymer is again cured by UV-light to fully cure the portions of thepolymer that will be the protrusions 2250. Once the protrusions arefully cured, the remaining uncured polymer (and partially cured polymer)can be removed to leave a forming structure having similarcharacteristics as those shown in FIGS. 15 and 17.

Other methods of making forming structures are contemplated, includingcreation via a molding technique, in which the forming structure 350 iscast in a negative impression mold, cured, and removed. Also, formingstructures could be formed by way of electroplating techniques, in whichsuccessive layers of material are built up into a suitable form.

One of the advantages to making forming structure 350 from a flexiblepolymeric material, such as the material described with respect to FIG.15 is that the forming structure is flexible enough to be utilized as acontinuous belt, much like a papermaking belt is used in theabove-mentioned Trokhan '289 patent. Such a continuous belt is referredto herein as a flexible “belted” forming structure. By “belted” is meantthat the forming structure is in the form of a continuous, flexible bandof material, much like a conveyor belt, as opposed to a relatively rigidtubular drum-shaped structure. FIG. 21 shows in simplified schematicrepresentation one embodiment of a process for making a polymeric web 80of the invention using a flexible belted forming structure 351. Asshown, belted forming structure 351 can be a continuous belted memberguided and held tensioned by various rollers, e.g., rollers 610. Beltedforming structure 351 is guided over forming drum 518. While on formingdrum 518 belted forming structure is supported by forming drum 518 andprecursor film 120 is supported on forming structure 351. The formationof web 80 on forming structure 351 proceeds the same way as describedabove with respect to FIG. 9 and forming drum 350. Therefore, precursorweb 120 can be subjected to liquid jet 540, (or jets) as well as dryingmeans 590 (or drying/annealing means). However, in the process describedschematically in FIG. 21, drying means 590 on forming drum 518 isoptional, because drying (and/or annealing) is provided for elsewhere inthe process, as described more fully below.

As can be seen in FIG. 21, belted forming structure 351 does not simplyrotate on forming drum 518 but is guided onto and off of forming drum518. As belted forming structure 351 is guided onto forming drum 518 itis dry. After belted forming structure 351 is supported by forming drum518, or concurrently therewith, precursor web 120 is guided over beltedforming structure 351 and hydroformed as described above. After passingdrying means 590 the belted forming structure 351 and athree-dimensional, apertured, formed film web 80 of the presentinvention are guided off of forming drum 518 together. That is, polymerweb 80 is intimately in contact with and supported by belted formingstructure 351. This permits further processing, such as drying orannealing, if necessary, to take place while the polymer web 80 is stillsupported by the belted forming structure 351. In this manner, polymerweb 80 can endure much greater work without collapsing, tearing, orotherwise deforming in a negative manner.

Belted forming structure 351 and polymer web 80 are guided in thedirection indicated in FIG. 21, i.e., the machine direction, to athrough-air drying means 800. Through air drying means can be in theform of a rotating drum as shown in FIG. 21, but can be in any of otherknown configurations. Drying means 800 preferably utilizes air which isforced through polymer web 80 and belted forming structure 351 to effectdrying of the web. However, other drying means are contemplated, such asthe use of capillary drying or limited orifice drying techniques commonin the papermaking industry for drying paper webs.

Drying means shown in FIG. 21 comprises rotating porous drying drum 802.As belted forming structure 351 and polymeric web 80 are supported bydrying drum 802 a drying fluid, such as air, is forced through beltedforming structure 351 and polymeric web 80. Fluid, such as air, can beforced from the outside to the inside of drying drum 802, as shown inFIG. 21, or it can be forced from the inside to the outside. In eitherconfiguration, the point is that the fluid effects drying of polymericweb 80 while web 80 remains fully supported on belted forming structure351. Drying drum dimensions, fluid flow rates, fluid moisture content,drying drum rotation velocity can all be adjusted as necessary to ensureadequate drying of polymeric web 80 prior to being guided off of dryingdrum 802.

Drying drum 802 can have a vacuum chamber 808 to aid in fluid flowthrough polymeric web 80 and belted forming structure 351. Additionally,fluid removal means can be utilized to remove liquid removed frompolymeric web 80. Fluid removal means can include a simple drain informing drum 802, but can also include active removal via pumps as isknown in the art to recycle water back to the hydroforming apparatus.Drying drum 802 can have a positive pressure chamber 810 which aids inremoving excess moisture from the surface of forming drum 802 prior torepeating the process of supporting belted forming structure 351. Liquidremoved can be simply captured in container 804 and removedappropriately, such as by draining into a water recycle system.

Once polymeric web 80 and belted forming structure 351 are guided off ofdrying drum 802, polymeric web 80 is separated from belted formingstructure 351 at separation point 830. From this point polymeric web 80may be, if necessary, subjected to additional drying, such as by radiantheat drying means 840, and likewise, belted forming structure may besubjected to additional drying means, such as forced air drying means850. In all cases, other drying means as suitable under the processingconditions can be utilized as necessary to ensure that polymeric web 80is sufficiently dry prior to final processing into roll stock and beltedforming structure 351 is sufficiently dry to avoid introducing moistureinto the interior of hair like fibrils 225 of polymeric web 80.Sufficiently dry means dry enough such that post-manufacture moisturerelated problems such as mold or mildew in the polymeric web areminimized or eliminated.

1. A polymeric web comprising a polymeric film, said web exhibiting asoft and silky tactile impression on at least one side thereof, saidsilky feeling side of said web exhibiting a pattern of discretegenerally columnar protruded extensions, wherein said generally columnarprotruded extensions are an integral extension of said film, each saidgenerally columnar protruded extension being formed by local plasticdeformation of said film and having a side wall defining an openproximal portion and a closed distal portion, and having a maximumlateral cross-sectional dimension at or near said open proximal portion,wherein said generally columnar protruded extensions exhibit an averagediameter of between 50 microns (0.02 inch) and 130 microns (0.005 inch),and an aspect ratio of from 1 to
 3. 2. The web of claim 1, wherein saidgenerally columnar protruded extensions are substantially cylindricallyshaped.
 3. The web of claim 1, wherein said generally columnar protrudedextensions have a substantially non-uniform lateral cross section. 4.The web of claim 1, wherein said generally columnar protruded extensionshave a largest lateral cross-sectional dimension at said proximalportion, wherein said lateral cross-sectional dimensions steadilydecrease to said distal portion.
 5. The web of claim 1, wherein saidsidewalls of said generally columnar protruded extensions decrease inthickness with increasing amplitude of said generally columnar protrudedextensions.
 6. The web of claim 1, wherein said web comprises amultilayer polymeric film.
 7. The web of claim 6, wherein said webcomprises a surfactant in at least one of said layers.
 8. The web ofclaim 6, wherein said web comprises particulate matter in at least onelayer.
 9. The web of claim 8, wherein said generally columnar protrudedextensions exhibit a roughened surface near said distal portion.
 10. Theweb of claim 1, wherein said generally columnar protruded extensionshave an average center-to-center spacing of from about 100 microns to250 microns (0.004 inch to 0.0 10 inch).
 11. The web of claim 1, whereinsaid silky feeling side of said web exhibits at least about 1500 of saidgenerally columnar protruded extensions per square centimeter.
 12. Theweb of claim 1, wherein said web further comprises a macroscopicallyexpanded, three-dimensional pattern of interconnecting members definingmacroscopic surface aberrations, said macroscopic surface aberrationsdefining a first surface in a first plane of said web, and a secondsurface in a second plane of said web.
 13. The web of claim 12, whereinsaid macroscopic surface aberrations are primary apertures, said primaryapertures placing said first surface and said second surface in fluidcommunication.
 14. The web of claim 12, wherein said generally columnarprotruded extensions are each a protruded extension of only said firstsurface.
 15. A three-dimensional polymeric web exhibiting a soft andsilky tactile impression on at least one surface thereof, said webcomprising a macroscopically expanded pattern of interconnecting membersdefining macroscopic surface aberrations, said macroscopic surfaceaberrations defining a first surface in a first plane of said web, and asecond surface in a second plane of said web, said first surface of saidweb exhibiting a pattern of discrete generally columnar protrudedextensions, each of said generally columnar protruded extensions beingan integral extension of said first surface and formed by local plasticdeformation of said web and having a side wall defining an open proximalportion and a closed distal portion, said generally columnar protrudedextensions having a height and an average lateral cross-sectionaldiameter at ½ said height of between 50 microns (0.002 inch) and 130microns (0.005 inch), an average center-to-center spacing of from about100 microns to 250 microns (0.004 inch to 0.0 10 inch), and an aspectratio from 1 to
 3. 16. The web of claim 15, wherein said generallycolumnar protruded extensions are substantially cylindrically shaped.17. The web of claim 15, wherein said generally columnar protrudedextensions have a substantially non-uniform lateral cross section. 18.The web of claim 15, wherein said generally columnar protrudedextensions have a maximum lateral cross-sectional dimension at saidproximal portion, and wherein said lateral cross-sectional dimensionssteadily decrease to said distal portion.
 19. The web of claim 15.wherein said sidewalls of said generally columnar protruded extensionsdecrease in thickness with increasing amplitude of said generallycolumnar protruded extensions.
 20. The web of claim 19, wherein said webcomprises a surfactant in at least one of said layers.
 21. The web ofclaim 15, wherein said web comprises a multilayer polymeric film. 22.The web of claim 20, wherein said web comprises particulate matter in atleast one layer.
 23. The web of claim 20, wherein said generallycolumnar protruded extensions exhibit a roughened surface near saiddistal portion.
 24. The web of claim 15, wherein said web comprises atleast one region having a least about 1500 of said generally columnarprotruded extensions per square centimeter of first surface.
 25. Adisposable absorbent article comprising a fluid pervious polymeric webexhibiting a soft and silky tactile impression on at least one surfacethereof, said silky feeling surface of said web exhibiting a pattern ofdiscrete generally columnar protruded extensions, wherein said generallycolumnar protruded extensions are an integral extension of said websurface, each said generally columnar protruded extension being formedby local plastic deformation of said film and having a side walldefining an open proximal portion and a closed distal portion, andhaving a maximum lateral cross-sectional dimension at or near said openproximal portion, wherein said generally columnar protruded extensionsexhibit an average diameter of between 50 microns (0.002 inch) and 130microns (0.005 inch), and an aspect ratio of from 1 to
 3. 26. Thedisposable absorbent article of claim 25, wherein said article comprisesa catamenial device.
 27. The disposable absorbent article of claim 26,wherein said catamenial device comprises a sanitary napkin.
 28. Thedisposable absorbent article of claim 25, wherein said polymeric webcomprises a topsheet of said article.